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Old 01-13-2009, 03:57 PM   #1
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Default Making and Installing a shift kit. 4t65-hd transmission

Time to install that street/strip shift kit? Feeling a little stressed about it? Well, don't. It'* a easy job, just make sure you read and follow the directions very closely. Read, look, read again. Check it a third time just to make sure.

Care to make your own shift kit? It'* very easy and cheap. Go to your local hardware store and pick up some tube. You will need the inside diameter to be .25", this must be the correct size. The outside diameter should be .375" This can be a little larger with out causing problems, but no larger then .5" outside diameter.

Now cut 3 of tubes at .75" long, and 1 tube .5" long.

You will also need to get a filter and gasket.

Here is a picture of a metal spacer and a plastic spacer, both will work fine.


You will need a inch pound torque wrench.

Jack up the front of your car and use jack stands.

Or put it up on ramps.


Get everything laid out, fluid, the kit, even a extra gasket. Mine had a reusable gasket so I didn't need one.


Locate your tranny pan.


It'* going to be a big mess. Get a large pan to catch the fluid, a few extras are a good idea. Crack the bolts on the pan loose. Loosen the back bolts a bit more so it will drain from that area. When the fluid stops you can start to remove all the bolts.



Remove the pan and set it aside


Wipe it down good. Check the magnet for any metal shavings. If you see a lot of shavings, I suggest not installing the kit at this time.


Back under the car you will see the shift modulator in the tranny


Remove the 4 bolts holding it in the tranny. One is on the left side and the other three are along the right side

Clean everything up and inspect for damage or wear. Then place on a clean work area and remove the last of the bolts holding the modulator together and open it up


Remove the pistons, make sure they go back in the same cylinder. Use a fine grit wet sand sand paper to clean up the inside walls of the cylinders. Just want to scuff it up a little bit. Then place the 3/4" spacer on the bottom of both cylinders.


Put the pistons back in the cylinders and put a 1/2" spacer in the 1-2 cylinder.

and a 3/4" spacer in the 2-3 cylinder


Now put the cover back on the modulator and torque all bolts to required amount.


Now reinstall the modulator in the tranny connecting the lines and then line everything up and torque to the correct amount as listed in the directions. As you lift it up each tube will line up.



Then install the 4 bolts holding the modulator in place and torque to required amount.





These diagrams came from the FSM
This little strip of metal likes to fall out real easy. Watch for it, make sure it'* in place before you close up the transmission. It may be in the pan with the transmission oil.


For reference here is a diagram of the shift modulator.


Install your new filter.



Now put your pan in place and get a few bolts started. then snug up each bolt


Now with a clicker type inch pound torque wrench torque each bolt to 120 inch pounds. That'* inch pounds, NOT foot pounds


Once the pan is torqued you will need to fill the tranny with the correct fluid. You will do this threw the dip stick tube. You will need a funnel. Make sure you get GM fluid. You will need to add fluid, then start the engine and go threw the gears, then add more fluid and go threw the gears again. It will take some time to fill the tranny back up.


Congratulations, you have now installed your shift kit. Your shifts will be much firmer and quicker.

This kit has also been shown to remove a fair amount of KR.

Last edited by Danthurs; 01-26-2009 at 01:05 PM.
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3.8, 3800, 4t65-hd, bonneville, gm 3.8, gm 3800, performance, shift kit, transmission

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